Antistatic subbing layer for dye-donor element used in thermal dye transfer

Abstract: A dye-donor element for thermal dye transfer comprising a support having on one side thereof, in order, a subbing layer and a dye layer, and wherein the subbing layer has antistatic properties and comprises a copolymer having the formula: wherein: A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups; B represents units of a copolymerizable α,β-ethylenically unsaturated monomer; L is a carboxylic group or an aromatic ring; Q is N or P; R¹, R² and R³ each independently represents an alkyl or cycloalkyl group having from 1 to 20 carbon atoms or an aryl or aralkyl group having from 6 to 10 carbon atoms; R⁴ is H or CH₃; M is an anion; n is an integer of from 1 to 6; x is from 0 to 20 mole %; y is from 0 to 90 mole %; and z is from 10 to 100 mole %.

Description: This invention relates to dye donor elements used in thermal dye transfer, and more particularly to the use of a certain subbing layer for the dye layer, the subbing layer having antistatic properties. In recent years, thermal transfer systems have been developed to obtain prints from pictures which have been generated electronically from a color video camera. According to one way of obtaining such prints, an electronic picture is first subjected to color separation by color filters. The respective color-separated images are then converted into electrical signals. These signals are then operated on to produce cyan, magenta and yellow electrical signals. These signals are then transmitted to a thermal printer. To obtain the print, a cyan, magenta or yellow dye-donor element is placed face-to-face with a dye-receiving element. The two are then inserted between a thermal printing head and a platen roller. A line-type thermal printing head is used to apply heat from the back of the dye-donor sheet. The thermal printing head has many heating elements and is heated up sequentially in response to the cyan, magenta and yellow signals. The process is then repeated for the other two colors. A color hard copy is thus obtained which corresponds to the original picture viewed on a screen. Further details of this process and an apparatus for carrying it out are contained in U.S. Patent No. 4,621,271. For media transport and handling, an antistatic layer is usually needed in a dye-donor element, since there is dust accumulation on a statically charged surface and potential sparking which may destroy heating elements in the thermal head. The antistatic material is usually located in or over a slipping layer coated on the back side of the dye-donor element. U.S. Patent No. 4,737,486 discloses the use of a titanium alkoxide as a subbing layer between a support and a dye layer. While this material is a good subbing layer for adhesion, problems have arisen with hydrolytic instability, and the layer is difficult to coat in a reproducible manner. It has also been observed that degradation of dyes in the dye-donor element can occur when titanium alkoxides are used in a subbing layer. U.S. Patent 5,147,843 discloses the use of mixtures of poly(vinyl alcohol) and poly(vinyl pyrrolidinone) as a subbing layer. Although the mixture disclosed in this patent is a good subbing layer, it does not provide any antistatic properties to the dye-donor element. Research Disclosure article 33483, February 1992, pages 155-159 discloses the use of various antistatic agents, such as quaternary ammonium salts or polymers, which may be mixed with a hydrophilic colloid binder, and used in thermal dye transfer elements. However, there is no disclosure in this reference of the use of these materials in a subbing layer for a dye layer. It is an object of this invention to provide a subbing layer for a dye layer which has good adhesion. It is another object of this invention to provide a subbing layer for a dye layer which has good hydrolytic stability. It is yet another object of this invention to provide a subbing layer which provides increased density of the thermally transferred dyes. It is still another object of this invention to provide a subbing layer for a dye layer which has antistatic properties, thus not requiring the dye-donor element to have a separate antistatic layer. These and other objects are achieved in accordance with this invention which relates to a dye-donor element for thermal dye transfer comprising a support having on one side thereof, in order, a subbing layer and a dye layer, and wherein the subbing layer has antistatic properties and comprises a copolymer having the formula: wherein: A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups; B represents units of a copolymerizable α,β-ethylenically unsaturated monomer; L is a carboxylic group or an aromatic ring, such as Q is N or P; R 1 , R 2 and R 3 each independently represents an alkyl or cycloalkyl group having from 1 to 20 carbon atoms, such as methyl, ethyl or cyclohexyl; or an aryl or aralkyl group having from 6 to 10 carbon atoms, such as phenyl or methylphenyl; R 4 is H or CH 3 ; M is an anion; n is an integer of from 1 to 6; x is from 0 to 20 mole %; y is from 0 to 90 mole %; and z is from 10 to 100 mole %. Examples of copolymers having the above formula include poly(N-vinyl-benzyl-N,N,N-trimethylammonium chloride-co-ethylene glycol dimethacrylate) (93:7 mole percent); poly[2-(N,N,N-trimethylammonium)ethyl methacrylate methosulfate]; poly[2-(N,N,N-trimethylammonium)ethyl acrylate methosulfate]; poly[2-(N,N-diethylamino)ethyl methacrylate hydrogen chloride-co-ethylene glycol dimethacrylate] (93:7 mole percent); etc. In the above formula, A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups such as divinylbenzene, allyl acrylate, allyl methacrylate, N-allylmethacrylamide, 4,4'-isopropylidenediphenylene diacrylate, 1,3-butylene diacrylate, 1,3-butylene dimethacrylate, 1,4-cyclohexylenedimethylene dimethacrylate, diethylene glycol dimethacrylate, diisopropylidene glycol dimethacrylate, divinyloxymethane, ethylene glycol diacrylate, ethylene glycol dimethacrylate, ethylidene diacrylate, ethylidene dimethacrylate, 1,6-diacrylamidohexane, 1,6-hexamethylene diacrylate, 1,6-hexamethylene dimethacrylate, N,N'-methylenebisacrylamide, 2,2-dimethyl-1,3-trimethylene dimethacrylate, phenylethylene dimethacrylate, tetraethylene glycol dimethacrylate, tetramethylene diacrylate, tetramethylene dimethacrylate, 2,2,2-trichloroethylidene dimethacrylate, triethylene glycol diacrylate, triethylene glycol dimethacrylate, ethylidyne trimethacrylate, propylidyne triacrylate, vinyl allyloxyacetate, vinyl methacrylate, 1-vinyloxy-2-allyloxyethane and the like. In the above formula, B represents units of a copolymerizable α,β-ethylenically unsaturated monomer such as ethylene, propylene, 1-butene, isobutene, 2-methylpentene, 2-methylbutene, 1,1,4,4-tetramethyl-butadiene, styrene and α-methylstyrene; monoethylenically unsaturated esters of aliphatic acids such as vinyl acetate, isopropenyl acetate, allyl acetate, etc.; esters of ethylenically unsaturated mono- or dicarboxylic acids such as methyl methacrylate, ethyl acrylate, diethyl methylenemalonate, etc.; and monoethylenically unsaturated compounds such as acrylonitrile, allyl cyanide, and dienes such as butadiene and isoprene. In the above formula, M - is an anion such as bromide, chloride, sulfate, alkyl sulfate, p-toluenesulfonate, phosphate, dialkyl phosphate or similar anionic moiety. The subbing/antistat layer of the invention may be present in any concentration which is effective for the intended purpose. In general, good results have been attained using a laydown of from about 0.1 g/m 2 to about 0.2 g/m 2 . The polymeric material described above may be the sole component of the subbing layer, or it may be mixed with other conventional, organic polymeric materials used as subbing layers in thermal dye transfer elements such as poly(vinylpyrrolidinone) (PVP), methacrylate polymers, acrylate polymers, poly(vinyl acetal) resins, cellulosic materials, poly(alkylene oxides) or those materials disclosed in U.S. Patents 5,147,843, 4,716,144, 5,122,502 and 4,700,208. When the polymeric material described above is mixed with other conventional, organic polymeric materials, it is present in an amount of at least about 10 weight %, preferably 20-90 weight %. Any dye can be used in the dye layer of the dye-donor element of the invention provided it is transferable to the dye-receiving layer by the action of heat. Especially good results have been obtained with sublimable dyes such as or any of the dyes disclosed in U.S. Patent 4,541,830. The above dyes may be employed singly or in combination to obtain a monochrome. The dyes may be used at a coverage of from about 0.05 to about 1 g/m 2 and are preferably hydrophobic. The dye layer of the dye-donor element may be coated on the support or printed thereon by a printing technique such as a gravure process. A slipping layer may be used on the back side of the dye-donor element of the invention to prevent the printing head from sticking to the dye-donor element. Such a slipping layer would comprise either a solid or liquid lubricating material or mixtures thereof, with or without a polymeric binder or a surface-active agent. Preferred lubricating materials include oils or semi-crystalline organic solids that melt below 100°C such as poly(vinyl stearate), beeswax, perfluorinated alkyl ester polyethers, poly(caprolactone), silicone oil, poly(tetrafluoroethylene), carbowax, poly(ethylene glycols), or any of those materials disclosed in U. S. Patents 4,717,711; 4,717,712; 4,737,485; and 4,738,950. Suitable polymeric binders for the slipping layer include poly(vinyl alcohol-co-butyral), poly(vinyl alcohol-coacetal), poly(styrene), poly(vinyl acetate), cellulose acetate butyrate, cellulose acetate propionate, cellulose acetate or ethyl cellulose. The amount of the lubricating material to be used in the slipping layer depends largely on the type of lubricating material, but is generally in the range of about 0.001 to about 2 g/m 2 . If a polymeric binder is employed, the lubricating material is present in the range of 0.05 to 50 weight%, preferably 0.5 to 40 weight%, of the polymeric binder employed. Any material can be used as the support for the dye-donor element of the invention provided it is dimensionally stable and can withstand the heat of the thermal printing heads. Such materials include polyesters such as poly(ethylene terephthalate); polyamides; polycarbonates; glassine paper; condenser paper; cellulose esters; fluorine polymers; polyethers; polyacetals; polyolefins; and polyimides. The support generally has a thickness of from about 2 to about 30 µm. The dye-receiving element that is used with the dye-donor element of the invention usually comprises a support having thereon a dye image receiving layer. The support may be a transparent film such as a poly(ether sulfone), a polyimide, a cellulose ester such as cellulose acetate, a poly(vinyl alcohol-co-acetal) or a poly(ethylene terephthalate). The support for the dye-receiving element may also be reflective such as baryta-coated paper, polyethylene-coated paper, white polyester (polyester with white pigment incorporated therein), an ivory paper, a condenser paper or a synthetic paper such as DuPont Tyvek®. The dye image-receiving layer may comprise, for example, a polycarbonate, a polyurethane, a polyester, poly(vinyl chloride), poly(styrene-co-acrylonitrile), polycaprolactone or mixtures thereof. The dye image-receiving layer may be present in any amount which is effective for the intended purpose. In general, good results have been obtained at a concentration of from about 1 to about 5 g/m 2 . As noted above, the dye donor elements of the invention are used to form a dye transfer image. Such a process comprises imagewise heating a dye-donor element as described above and transferring a dye image to a dye receiving element to form the dye transfer image. The dye donor element of the invention may be used in sheet form or in a continuous roll or ribbon. If a continuous roll or ribbon is employed, it may have only one dye or may have alternating areas of other different dyes, such as sublimable cyan and/or magenta and/or yellow and/or black or other dyes. Such dyes are disclosed in U.S. Patent Nos. 4,541,830; 4,698,651; 4,695,287; 4,701,439; 4,757,046; 4,743,582; 4,769,360 and 4,753,922. Thus, one-, two-, three- or four-color elements (or higher numbers also) are included within the scope of the invention. In a preferred embodiment of the invention, the dye-donor element comprises a poly(ethylene terephthalate) support coated with sequential repeating areas of yellow, cyan and magenta dye, and the above process steps are sequentially performed for each color to obtain a three-color dye transfer image. Of course, when the process is only performed for a single color, then a monochrome dye transfer image is obtained. A thermal dye transfer assemblage of the invention comprises (a) a dye-donor element as described above, and (b) a dye-receiving element as described above, the dye receiving element being in a superposed relationship with the dye donor element so that the dye layer of the donor element is in contact with the dye image-receiving layer of the receiving element. The above assemblage comprising these two elements may be preassembled as an integral unit when a monochrome image is to be obtained. This may be done by temporarily adhering the two elements together at their margins. After transfer, the dye-receiving element is then peeled apart to reveal the dye transfer image. When a three-color image is to be obtained, the above assemblage is formed on three occasions during the time when heat is applied by the thermal printing head. After the first dye is transferred, the elements are peeled apart. A second dye-donor element (or another area of the donor element with a different dye area) is then brought in register with the dye-receiving element and the process is repeated. The third color is obtained in the same manner. The following examples are provided to illustrate the invention. Example 1 A) A control dye-donor element was prepared by coating on a 6 µm poly(ethylene terephthalate) support: 1) a subbing layer of a titanium tetra-n-butoxide (DuPont Tyzor TBT)® (0.11 g/m 2 ) from a n-propyl acetate and n-butyl alcohol solvent mixture, and 2) a dye layer containing the first cyan dye illustrated above (0.39 g/m 2 ), the second cyan dye illustrated above (0.11 g/m 2 ) in a cellulose acetate propionate (2.5% acetyl, 45% propionyl) binder (0.35 g/m 2 ) coated from a toluene, methanol and cyclopentanone solvent mixture. On the back side of the element were coated the following layers in sequence: 1) a subbing layer of a titanium tetra-n-butoxide (DuPont Tyzor TBT)® (0.11 g/m 2 ) from n-butyl alcohol solvent, and 2) a slipping layer containing an aminopropyldimethyl-terminated polydimethylsiloxane, PS513® (Petrarch Systems, Inc.) (0.018 g/m 2 ), a Montan wax dispersion (0.032 g/m 2 ), and p-toluenesulfonic acid (0.0003 g/m 2 ) in a cellulose acetate propionate (2.5% acetyl, 45% propionyl) binder (0.35 g/m 2 ) coated from a 66:29:5 mixture of toluene, methanol and cyclopentanone. B) Other elements, some according to the invention and some comparison elements, were prepared similar to A) except that they had the subbing layer as identified in Table 1. A dye receiving element was prepared by coating the following layers in the order recited over a white reflective support of titanium dioxide-pigmented polyethylene-overcoated paper stock: 1) a subbing layer of poly(acrylonitrile-co-vinylidene chloride-co-acrylic acid) (14:79:7 wt ratio) (0.08 g/m 2 ) coated from butanone; 2) a dye-receiving layer of a bisphenol A-polycarbonate resin, Makrolon 5700®, (Bayer AG), (1.61 g/m 2 ), T-1 polycarbonate (1.61 g/m 2 ) (structure below), dibutyl phthalate (0.32 g/m 2 ), diphenyl phthalate (0.32 g/m2) and FC-431® fluorocarbon surfactant (3M Corp.) (0.011 g/m 2 ) coated from dichloromethane; and 3) an overcoat layer of P-2 polycarbonate (0.22 g/m 2 ), (structure below), FC-431® fluorocarbon surfactant (3M Corp.) (0.016 g/m 2 ) and DC-510® silicone fluid (Dow Corning) (0.0 g/m 2 ) coated from dichloromethane. The dye side of the dye-donor elements described above, in a strip about 10 x 13 cm in area, was placed in contact with the dye image-receiving layer of a dye-receiver element, as described above, of the same area. The assemblage was clamped to a stepper-motor driving a 60 mm diameter rubber roller, and a TDK Thermal Head (No. L-231) (thermostatted at 30°C) was pressed with a force of 24.4 Newtons against the dye-donor element side of the assemblage pushing it against the rubber roller. The imaging electronics were activated causing the donor/receiver assemblage to be drawn between the printing head and the roller at 11.1 mm/sec. Coincidentally, the resistive elements in the thermal print head were pulsed for 128 microseconds/pulse at 128 microsecond intervals during the 16.9 millisecond/dot printing time. A stepped density image was generated by incrementally increasing the number of pulses/dot from 0 to 127. The voltage supplied to the print head was approximately 10.65 volts resulting in an instantaneous peak power of 0.232 watts/dot and a maximum total energy of 3.77 mjoules/dot. The Status A Red maximum density of each of the stepped images was read and recorded in Table 1 below. Adhesion of the dye layer was evaluated using a tape adhesion test. A small area (approximately 1.25 x 4.0 cm) of Scotch Magic Transparent Tape, #810, (3M Corp) was firmly pressed by hand onto the dye side of the donor. Upon manually pulling the tape, the amount of dye layer removed was estimated and related to adhesion. Ideally none of the dye layer would be removed. The following categories were established for evaluation: good - no layer removal fair - partial layer removal poor - substantial layer removal very poor - total layer removal Surface electrical resistivity (SER) was determined using a Hewlett Packard 16008A Resistivity Cell in conjunction with a HP4329A High Resistance Meter. The test voltage was 100V and surface resistivities in ohms were determined after a 1 min. charging. The lower the resistivity, the better the element is for antistatic properties. The following results were obtained: Subbing Layer Dmax Tape Adhesion log SER (Ω) Tyzor (Control) 2.60 Good 12.2 PVP/C-2 100:0 (Comparison) 2.40 Good >16 80:20 2.48 Good 11.5 36:65 2.60 Good 9.8 20:80 2.58 Good 9.7 10:90 2.60 Good 9.6 0:100 2.59 Fair 9.0 PVP/C-1 100:0 (Comparison) 2.40 Good >16 65:35 2.51 Good 10.5 35:65 2.59 Good 9.3 0:100 2.62 Good 8.3 C-3/C-1 100:0 (Comparison) 2.55 Fair >16 35:65 2.65 Good 10.0 PVA/C-1 100:0 (Comparison) 2.33 Good >16 35:65 2.53 Good 11.3 PVA/PVP/C-2 20:80:0 (Control) 2.59 Good >16 13:52:35 2.54 Good 11.4 7:28:65 2.59 Good 10.0 PVP = polyyinylpyrrolidinone PVA = poly(vinyl alcohol) C-1 = poly(n-vinylbenzyl-N,N,N-trimethylammonium chloride-co-ethylene glycol dimethacrylate) (93:7 mole %) C-2 = poly(2-N, N, N-trimethylammonium)ethyl methacrylate methosulfate) C-3 = a copolymer of n-butyl acrylate, 2-hydroxyethyl methacrylate, and methyl 2-acrylamido-2-methoxyacetate (50:25:25 wt. %) The above results show that the incorporation of a quaternary ammonium polymer into a subbing binder material according to the invention provides increased dye transfer efficiency and surface electrical resistivity. Example 2 This example is similar to Example 1 but uses different coverages of the subbing layer. The donor was prepared in a similar manner as described in Example 1 to give the following results: Subbing Material PVP/C-2 Laydown (g/m 2 ) Dmax Tape Adhesion log SER (Ω) 35:65 0.05 2.54 Good 10.3 35:65 0.11 2.52 Good 10.2 35:65 0.22 2.52 Good 9.8 The above results show that the subbing layer of the invention is effective at different coverages.

Claims: A dye-donor element for thermal dye transfer comprising a support having on one side thereof, in order, a subbing layer and a dye layer, and wherein the subbing layer has antistatic properties and comprises a copolymer having the formula: wherein: A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups; B represents units of a copolymerizable α,β-ethylenically unsaturated monomer; L is a carboxylic group or an aromatic ring; Q is N or P; R 1 , R 2 and R 3 each independently represents an alkyl or cycloalkyl group having from 1 to 20 carbon atoms or an aryl or aralkyl group having from 6 to 10 carbon atoms; R 4 is H or CH 3 ; M is an anion; n is an integer of from 1 to 6; x is from 0 to 20 mole %; y is from 0 to 90 mole %; and z is from 10 to 100 mole %. The element of Claim 1 wherein said copolymer is poly(N-vinylbenzyl-N,N,N-trimethyl-ammonium chloride-co-ethylene glycol dimethacrylate) (93:7 mole percent); poly[2-(N,N,N-trimethylammonium)-ethyl methacrylate methosulfate]; poly[2-(N,N,N-trimethylammonium)ethyl acrylate methosulfate]; or poly[2-(N,N-diethylamino)ethyl methacrylate hydrogen chloride-co-ethylene glycol dimethacrylate](93:7 mole percent). The element of Claim 1 wherein said subbing layer comprises a mixture of poly(vinylpyrrolidinone) and said copolymer. The element of Claim 3 wherein said copolymer is present in an amount of 20 to 90 weight percent of said mixture. A process of forming a dye transfer image comprising: (a) imagewise-heating a dye-donor element comprising a support having on one side thereof, in order, a subbing layer and a dye layer, and (b) transferring a dye image to a dye receiving element to form said dye transfer image, wherein said subbing layer has antistatic properties and comprises a copolymer having the formula: wherein: A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups; B represents units of a copolymerizable α,β-ethylenically unsaturated monomer; L is a carboxylic group or an aromatic ring; Q is N or P; R 1 , R 2 and R 3 each independently represents an alkyl or cycloalkyl group having from 1 to 20 carbon atoms or an aryl or aralkyl group having from 6 to 10 carbon atoms; R 4 is H or CH 3 ; M is an anion; n is an integer of from 1 to 6; x is from 0 to 20 mole %; y is from 0 to 90 mole %; and z is from 10 to 100 mole %. The process of Claim 5 wherein said copolymer is poly(N-vinylbenzyl-N,N,N-trimethylammonium chloride-co-ethylene glycol dimethacrylate) (93:7 mole percent); poly[2-(N,N,N-trimethylammonium)ethyl methacrylate methosulfate]; poly[2-(N,N,N-trimethylammonium)ethyl acrylate methosulfate]; or poly[2-(N,N-diethylamino)ethyl methacrylate hydrogen chloride-co-ethylene glycol dimethacrylate] (93:7 mole percent). The process of Claim 5 wherein said subbing layer comprises a mixture of poly(vinylpyrrolidinone) and said copolymer. The process of Claim 7 wherein said copolymer is present in an amount of 20 to 90 weight percent of said mixture. A thermal dye transfer assemblage comprising (a) a dye-donor element comprising a support having on one side thereof, in order, a subbing layer and a dye layer, and (b) a dye receiving element comprising a support having thereon a dye image-receiving layer, said dye-receiving element being in a superposed relationship with said dye-donor element so that said dye layer is in contact with said dye image-receiving layer, wherein said subbing layer has antistatic properties and comprises a copolymer having the formula: wherein: A represents units of an addition polymerizable monomer containing at least two ethylenically unsaturated groups; B represents units of a copolymerizable α,β-ethylenically unsaturated monomer; L is a carboxylic group or an aromatic ring; Q is N or P; R 1 , R 2 and R 3 each independently represents an alkyl or cycloalkyl group having from 1 to 20 carbon atoms or an aryl or aralkyl group having from 6 to 10 carbon atoms; R 4 is H or CH 3 ; M is an anion; n is an integer of from 1 to 6; x is from 0 to 20 mole %; y is from 0 to 90 mole %; and z is from 10 to 100 mole %. The assemblage of Claim 9 wherein said copolymer is poly(N-vinylbenzyl-N,N,N-trimethylammonium chloride-co-ethylene glycol dimethacrylate) (93:7 mole percent); poly[2-(N,N,N-trimethylammonium)ethyl methacrylate methosulfate]; poly[2-(N,N,N-trimethylammonium)ethyl acrylate methosulfate]; or poly[2-(N,N-diethylamino)ethyl methacrylate hydrogen chloride-co-ethylene glycol dimethacrylate] (93:7 mole percent).

Inventors: BAUER CHARLES LEO, BOWMAN WAYNE ARTHUR, BAUER, CHARLES LEO, BOWMAN, WAYNE ARTHUR, BAUER, CHARLES LEO, EASTMAN KODAK COMPANY, BOWMAN, WAYNE ARTHUR, EASTMAN KODAK COMPANY
Applicants: EASTMAN KODAK CO, EASTMAN KODAK COMPANY
Application year: 1994
Main classification: B41M5
IPC codes: B41M5, C09K3, C08L57, C08L25, C08L101